Subsea open-standard control systems and methods

ABSTRACT

This disclosure includes embodiments of a subsea open standard (SOS) control system and methods of operating and expanding the same that are suitable for controlling subsea production equipment directly from a topsides master control station (MCS). For example, this disclosure includes a network using an open and non-propriety networking protocol to send and receive control commands directly between the MCS and a subsea networked end device having a unique network address via a subsea network router module (SRM).

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No. 62/488,427, filed Apr. 21, 2017, the entire contents of which application are specifically incorporated by reference herein without disclaimer.

FIELD OF INVENTION

The present invention relates generally to controlling subsea equipment in connection with offshore drilling, completion, installation, intervention, and/or production components and equipment; and more particularly, but not by way of limitation, to systems and methods utilizing open standard communication protocols for controlling and/or monitoring such subsea equipment.

BACKGROUND

Many subsea Original Equipment Manufacturers (OEMs) sell custom subsea controls solutions to operators that utilize proprietary hardware, software, and custom communications protocols to achieve otherwise industry standard process automation functionality. These OEMs also provide aftermarket service and maintenance for their respective controls systems. Conventionally, each piece of controllable subsea equipment contains one subsea control module (SCM) that has a single unique network address. From a networking perspective, sensors and other devices are located “behind” or “below” the SCM in this configuration and are not uniquely visible on the network to the topsides equipment or personnel. The SCMs acts as a gatekeeper and bottleneck the flow of information from the various installed subsea devices connected to it by filtering data and interpreting topsides controls commands into discrete actions. Due to the proprietary nature of these equipment items and their interfaces, owners and operators of this equipment become “locked-in” to using the OEM's own aftermarket services for maintenance, modifications, and future field expansions. The fully custom and proprietary nature of this solution paradigm is not cost effective for operators as many of the core components necessary to achieve the same functionality have become commoditized. Drawbacks of such proprietary systems include the use of non-standard hardware, higher maintenance costs, a less reliable network, poor scalability, a non-adaptable and non-flexible field layout, and software that is not operator/user configurable.

SUMMARY

This application includes systems and methods utilizing open standard communication protocols for controlling and/or monitoring equipment at and/or functionally related to a subsea wellhead, such as, for example, subsea production equipment, distribution equipment, enhanced oil recovery equipment, pumping equipment, and any other process control or condition monitoring equipment.

Some embodiments of the present subsea open-standard control systems comprise: a topsides master control station (MCS); at least one subsea network router module (SRM); and at least one subsea networked end device connected to the at least one SRM. The topsides master control station (MCS) can comprise: a human-machine interface including a computing device having at least one processor configured to execute instructions, and a network interface configured to communicate commands to a network using an open and non-proprietary network protocol. Each subsea network router module (SRM) can comprise: a modular housing configured to be disposed on a subsea structure, and a plurality of network switches disposed within the housing, the network switches configured to operate using the open and non-proprietary networking protocol. Each subsea networked end device can have a unique network address and configured to communicate directly with the MCS via the at least one SRM using the open and non-proprietary networking protocol. Some embodiments of the present systems further comprise: at least one topsides hydraulic power unit configured to control hydraulic fluid flow to the at least one subsea networked end device.

Some embodiments of the present systems further comprise: at least one subsea power and communications unit configured to interface with the MCS and interface with at least one subsea umbilical to provide clean power and network communications to the at least one subsea umbilical. Some embodiments further comprise: at least one control umbilical reel configured to store, deploy, and retrieve the at least one subsea umbilical; and a plurality of sheaves configured to route the at least one subsea umbilical. Some embodiments further comprise: a topsides umbilical termination device having an I-tube configured to store, deploy, and retrieve the at least one subsea umbilical.

Some embodiments of the present systems further comprise: at least one subsea distribution unit (SDU) configured to connect the at least one SRM to the at least one subsea umbilical. In some embodiments, the at least one SDU further comprises at least one expansion port configured to connect an additional SRM to the network. In some embodiments, the system comprises a plurality of SRMs and a plurality of subsea networked end devices, where each of the plurality of subsea networked end devices is connected to a separate one of the plurality of SRMs and at least one of the plurality of SRMs is connected to the at least one SDU. In some embodiments, at least a portion of the plurality of subsea networked end devices are connected to the network in a daisy chain network configuration. In some embodiments, each of the plurality of subsea networked end devices is connected to the network via at least one redundant network connection in a mesh network configuration.

Some embodiments of the present systems further comprise: a plurality of multi quick connection (MQC) plates configured to: connect the at least one SDU to the at least one SRM, and connect the at least one SRM to the at least one subsea networked end device. Some embodiments further comprise: at least one remotely operated vehicle (ROV) configured to communicate directly with the MCS via the at least one SRM using the open and non-proprietary networking protocol. In some embodiments, the at least one ROV is configured to install and remove the plurality of MQC plates and the at least one SRM.

In some embodiments of the present systems: (i) the at least one SRM is configured to be directly mounted on the at least one subsea networked end device; (ii) the at least one SRM further comprises at least one connection port configured to connect an additional subsea networked end device having a unique network address to the at least one SRM; and/or (iii) the MCS is disposed in a climate controlled enclosure.

In some embodiments of the present methods (e.g., of operating a subsea open-standard control system comprising a topsides master control station (MCS) including a computing device having at least one processor), the method comprises: receiving, by the MCS, at least one communication indicating that at least one subsea network router module (SRM) and at least one subsea networked end device having a unique network address are connected to a network using an open and non-proprietary networking protocol; receiving, by the MCS via a human-machine interface, at least one control command for controlling the at least one subsea networked end device; sending, by executing one or more instructions with the at least one processor, the at least one control command to the at least one SRM using the open and non-proprietary networking protocol, where the at least one SRM routes the at least one control command to the at least one subsea networked end device and enables direct communication between the MCS and the at least one subsea networked end device; and implementing a function of the at least one subsea networked end device corresponding to the at least one control command. In some embodiments, the at least one SRM comprises at least one connection port configured to connect an additional subsea networked end device having a unique network address to the at least one SRM via a separate network connection, the separate network connection using the open and non-proprietary networking protocol.

In some embodiments of the present methods, at least one subsea distribution unit (SDU) comprises at least one expansion port configured to connect an additional SRM to the network via a separate network connection, the separate network connection using the open and non-proprietary networking protocol. In some embodiments, each of a plurality of subsea networked end devices is connected to a separate one of a plurality of SRMs and at least one of the plurality of SRMs is connected to the at least one SDU. In some embodiments, at least a portion of the plurality of subsea networked end devices is connected to the network in a daisy chain configuration. In some embodiments, each of the plurality of subsea networked end devices is connected to the network via at least one redundant network connection in a mesh network configuration. Some embodiments further comprise: analyzing, by the at least one SRM, a destination network address of the at least one control command; matching, by the at least one SRM, the destination network address of the at least one control command to the unique network address of the at least one subsea networked end device; and routing, by the at least one SRM, the at least one control command to the subsea networked end device having the unique network address that matches the destination network address. Some embodiments further comprise: controlling, by the MCS, hydraulic fluid flow to the at least one subsea networked end device.

Some embodiments of the present methods further comprise: sending, by the MCS via the at least one SRM, the at least one control command to at least one remotely operated vehicle (ROV) configured to communicate directly with the MCS via the open and non-proprietary networking protocol; and piloting the ROV using the MCS. Some embodiments further comprise: connecting, using the at least one ROV, an additional subsea networked end device to an at least one connection port with at least one multi quick connection (MQC) plate. Some embodiments further comprise: connecting, using the at least one ROV, an additional subsea networked end device to an at least one expansion port with at least one multi quick connection (MQC) plate. Some embodiments further comprise: disconnecting, using the at least one ROV, the additional subsea networked end device from the at least one connection port. Some embodiments further comprise: disconnecting, using the at least one ROV, the additional subsea networked end device from the at least one expansion port.

Some embodiments of the present methods further comprise: monitoring a state of the at least one subsea networked end device.

In some embodiments of the present methods (e.g., of operating a subsea open-standard control system comprising a topsides master control station (MCS) including a computing device having at least one processor), the method comprises: determining, by the MCS, that a network using an open and non-proprietary networking protocol can support an addition of at least one expansion network node to the network, the at least one expansion network node including one or more of a subsea network router module (SRM) and a subsea networked end device having a unique network address; and expanding, by the MCS, the network by adding the at least one expansion network node to the network. In some embodiments, expanding the network includes attaching the SRM to an expansion port of a subsea distribution unit (SDU) connected to the network. In some embodiments, expanding the network includes attaching the subsea networked end device to a connection port of a SRM connected to the network. In some embodiments, expanding the network includes connecting the at least one expansion network node to the network in a daisy chain network configuration. Some embodiments further comprise: adding a redundant network connection to the at least one expansion network node in a mesh network configuration.

In some embodiments of the present methods (e.g., of operating a subsea open-standard control system comprising a topsides master control station (MCS) including a computing device having at least one processor), the method comprises: sending, by the MCS via an open and non-proprietary networking protocol, at least one control command directly to a subsea networked end device connected to a network, where the at least one control command is routed to the subsea networked end device by a subsea network router module (SRM) using a unique network address of the subsea networked end device. In some embodiments, the at least one control command is sent to the subsea networked end device from the MCS without sending the at least one control command through a subsea control module (SCM).

The term “coupled” is defined as connected, although not necessarily directly, and not necessarily mechanically; two items that are “coupled” may be unitary with each other. The terms “a” and “an” are defined as one or more unless this disclosure explicitly requires otherwise. The term “substantially” is defined as largely but not necessarily wholly what is specified (and includes what is specified; e.g., substantially 90 degrees includes 90 degrees and substantially parallel includes parallel), as understood by a person of ordinary skill in the art. In any disclosed embodiment, the term “substantially” may be substituted with “within [a percentage] of” what is specified, where the percentage includes 0.1, 1, 5, and 10 percent.

Further, a device or system that is configured in a certain way is configured in at least that way, but it can also be configured in other ways than those specifically described.

The terms “comprise” (and any form of comprise, such as “comprises” and “comprising”), “have” (and any form of have, such as “has” and “having”), and “include” (and any form of include, such as “includes” and “including”) are open-ended linking verbs. As a result, an apparatus that “comprises,” “has,” or “includes” one or more elements possesses those one or more elements, but is not limited to possessing only those elements. Likewise, a method that “comprises,” “has,” or “includes” one or more steps possesses those one or more steps, but is not limited to possessing only those one or more steps.

Any embodiment of any of the apparatuses, systems, and methods can consist of or consist essentially of—rather than comprise/include/have—any of the described steps, elements, and/or features. Thus, in any of the claims, the term “consisting of” or “consisting essentially of” can be substituted for any of the open-ended linking verbs recited above, in order to change the scope of a given claim from what it would otherwise be using the open-ended linking verb.

The feature or features of one embodiment may be applied to other embodiments, even though not described or illustrated, unless expressly prohibited by this disclosure or the nature of the embodiments.

Some details associated with the embodiments are described above and others are described below.

BRIEF DESCRIPTION OF THE DRAWINGS

The following drawings illustrate by way of example and not limitation. For the sake of brevity and clarity, every feature of a given structure is not always labeled in every figure in which that structure appears. Identical reference numbers do not necessarily indicate an identical structure. Rather, the same reference number may be used to indicate a similar feature or a feature with similar functionality, as may non-identical reference numbers. The figures are drawn to scale for at least the embodiments shown.

FIG. 1 depicts an exemplary system diagram of a subsea open standard (SOS) control system according to an embodiment of the disclosure.

FIG. 2 depicts an exemplary subsea Christmas tree for use with the control system according to an embodiment of the disclosure.

FIG. 3 depicts an exemplary umbilical termination unit/subsea distribution unit (UTA/SDU) for use with the control system according to an embodiment of the disclosure.

FIG. 4 depicts an exemplary subsea network router module (SRM) for use with the control system according to an embodiment of the disclosure.

FIG. 5 depicts an exemplary multiple quick connect (MQC) plate for use with the control system according to an embodiment of the disclosure.

FIG. 6 depicts an exemplary system diagram of a subsea open-standard control system having a daisy chain configuration according to an embodiment of the disclosure.

FIG. 7A depicts an exemplary system flowchart of an operation of a conventional subsea control system.

FIG. 7B depicts an exemplary system flowchart of an operation of a subsea open-standard control system according to an embodiment of the disclosure.

FIG. 8 depicts an exemplary control method implemented by a subsea open-standard control system according to an embodiment of the disclosure.

FIG. 9 depicts an exemplary routing method implemented by a subsea open-standard control system according to an embodiment of the disclosure.

FIG. 10 depicts an exemplary remote operating vehicle (ROV) control method implemented by a subsea open-standard control system according to an embodiment of the disclosure.

DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

The embodiments disclosed herein describe a subsea control system that networks topsides and subsea hardware together using open standard, non-proprietary communications protocols with modular, non-proprietary end devices and network routing hardware. This type of communications infrastructure eliminates the need for a proprietary and custom SCM solution. Instead, at least one Subsea Router Module (SRM) is installed subsea to pass information and control commands among various networked end devices. In the embodiments disclosed, the networked end devices comprise various types of subsea production equipment such as pressure and temperature sensors, sand detectors, chokes, downhole (DH) gauges, cameras, manifolds, Christmas trees, UTA/SDUs, and ROVs, among others. In the embodiments shown, each networked end device is individually visible to the topsides equipment and personnel, which enables direct control of subsea devices from a topsides Master Control Station (MCS). The SOS system uses open standard communication protocols, avoids data bottlenecks, uses standard hardware and user-configurable software, has lower maintenance costs, achieves heightened network reliability, is scalable, and enables an adaptable and flexible field layout. Accordingly, this SOS infrastructure enables cost effective long term operations when maintenance, modifications, and future field expansions are considered. For purposes of this disclosure, an open standard communication protocol is an open and non-proprietary networking protocol that has been standardized by a governing body such as the Institute of Electrical and Electronics Engineers (IEEE) and does not require a proprietary interface or gateway to translate between different nodes on the network.

Referring now to the drawings, and more particularly to FIG. 1, shown there and designated by the reference numeral 100 is an exemplary system diagram of a subsea open standard (SOS) control system according to an embodiment of the disclosure. As shown, system 100 includes various subsea production elements such as a riser 104, a pipeline end termination unit (PLET) 108, one or more flowline jumpers 112, a manifold 116, and one or more Christmas trees 120. In the embodiment shown, flowline jumpers 112 are coupled to the subsea production elements with diver-less connection devices 124. In the embodiment shown, these subsea production elements are controlled by various SOS control system elements including topsides elements such as a MCS 128, a hydraulic power unit (HPU) 132, a subsea power and communications unit (SPCU) 136, and an umbilical reel 140. In the embodiment shown, subsea SOS control system elements include an umbilical 144, a UTA/SDU 148, one or more jumpers/flying leads 152, one or more SRMs 156, one or more networked end devices 160, and an ROV 164. In some embodiments, umbilical 144 can be deployed with an alternative deployment device other than umbilical reel 140 and/or sheaves. In some embodiments, this alternative device can be a conventional termination on the topsides where a dynamic portion of umbilical 144 is pulled through an I-tube affixed to the hull of a topsides platform or vessel. In the embodiment shown, UTA/SDU 148 is a single integrated piece of equipment. In some embodiments, the SDU can be a stand-alone piece of equipment separate from the UTA. In other embodiments, the SDU can be combined and/or integrated with other subsea equipment elements such as PLET 108 or manifold 116.

In the embodiment shown, system 100 configures existing hardware and software components in a subsea oil and gas field development such that human operators on a topsides vessel or platform can have direct network connectivity to individual networked end devices 160 installed on a subsea infrastructure. In the embodiment shown, the networked end devices 160 themselves, not an SCM or equivalent module, are directly connected to a network bus using an open and non-proprietary protocol such as Ethernet and/or other protocols using TCP/IP, and standard network routing switch gear. Each piece of subsea production equipment such as manifold 116 or Christmas tree 120 has at least one “unintelligent” SRM 156 to facilitate network traffic. In the embodiment shown, each individual networked end device 160 installed on the subsea production equipment has a unique network address. In the embodiment shown, topside operators can customize user-configurable software running on the topsides SOS equipment that sends and receives data across the network. In the embodiment shown, additional subsea hardware devices can be added to an existing field network by connecting them to a subsea communications bus at any SRM 156 and/or an expansion port included on one of the subsea equipment devices such as Christmas tree 120 or UTA/SDU 148. Additionally, changes to software and/or control configurations can be made in real-time on the topsides platform due to the open standard nature of the network. System 100 therefore provides an increase in system performance, reliability, and flexibility over currently available OEM control and monitoring systems.

In the embodiment shown, MCS 128 enables a topside operator to control all of the networked subsea end devices directly via a human-machine interface (HMI). In the embodiment shown, MCS 128 includes at least one computer device having at least one processor configured to execute software and/or program instructions. In some embodiments, the HMI and the computer device can be a part of the same hardware element. A topsides operator can enter control commands into the HMI for controlling one or more of networked end devices 160. The computer device interprets the operator commands received from the HMI and transmits those commands to the network via a network interface. In some embodiments, the network interface and the computer device can be a part of the same hardware element. In the embodiment shown, the software and/or program instructions are user-configurable and utilize open and non-proprietary network standards for direct communications between MCS 128 and networked end devices 160. In some embodiments of MCS 128, a workstation can be provided for topsides operators to interface with the HMI. In some embodiments of MCS 128, a climate-controlled enclosure can be provided to protect the operator and MCS equipment from the environment and provide suitable working conditions. In the embodiment shown, MCS 128 includes all necessary hardware and accessories needed to interface with rig/platform/boat power and communications systems. This includes equipment such as uninterruptable power supplies (UPS), surge protectors, and other conditioning devices to “clean” power or network lines. In the embodiment shown, MCS 128 includes all necessary hardware and accessories to interface with all topsides and subsea production equipment such as manifold 116 and one or more Christmas trees 120 associated with the overall control system.

In the embodiment shown, topsides HPU 132 provides power for all hydraulic pressure and volumes necessary for the function of the subsea production equipment. In the embodiment shown, HPU 132 is controlled by MCS 128 and contains all electronic or electromechanical features necessary to enable remote control and monitoring of the HPU 132 from MCS 128 or other topsides rig/platform/boat interface.

In the embodiment shown, topsides SPCU 136 provides clean power and network communications to a subsea umbilical 144 at the required voltages and signal strengths to meet operational demands. In the embodiment shown, SPCU 136 includes the use of subcomponents such as transformers, analog, digital, and optical modems, line conditioners, surge protectors, and/or any other electrical or mechanical device needed to achieve the required output characteristics. In the embodiment shown, SPCU 136 interfaces with the umbilical 144 via an umbilical termination assembly. SPCU 136 also interfaces with and is controlled by MCS 128 via standard topsides connections and routings. In some embodiments, SPCU 136 can be housed inside or outside of the MCS 128 enclosure depending on project requirements.

In the embodiment shown, umbilical reel 140 enables the storing, deploying, and retrieving of the subsea umbilical 144. Umbilical reel 140 also provides a practical means of interfacing between umbilical 144 and other associated pieces of the topsides control system such as MCS 128, HPU 132, and/or the umbilical termination assembly that interfaces umbilical 144 with SPCU 136. In the embodiment shown, umbilical reel 140 interfaces with and is controlled by MCS 128. In some embodiments, umbilical reel 140 can include one or more sheaves and/or other associated hardware for facilitating the routing of umbilical 144 overboard in a manner consistent with the mechanical limitations of umbilical 144. In some embodiments, an alternative deployment device (e.g., conventional I-tube configuration) other than umbilical reel 140 can be used to interface between umbilical 144 and the topsides control system components. In the embodiment shown, umbilical 144 contains thermal insulation, buoyancy, and/or bend stiffening/restricting technology and provides the main connection between topsides and subsea equipment elements.

In the embodiment shown, UTA/SDU 148 is the termination point of umbilical 144 and provides connections for one or more controls jumpers/flying leads 152 that connect UTA/SDU 148 to the rest of the subsea equipment infrastructure via one or more SRMs 156. In some embodiments, UTA/SDU 148 has various numbers of MQC connections and/or other types of connections to meet specific project requirements. These MQC connections can include a connection between umbilical 144 and UTA/SDU 148, a connection between UTA/SDU 148 and manifold 116, a connection between UTA/SDU 148 and SRM 156, and one or more expansion ports for connecting UTA/SDU 148 to additional SRMs 156. In some embodiments, UTA/SDU 148 can include various networked end devices 160 onboard such as sensors based on project requirements.

In the embodiment shown, SRMs 156 provide the network switching functions that control the various subsea equipment elements. In some embodiments, a single SRM 156 can rout control commands from MCS 128 to all of the networked end units 160. In the embodiment shown, multiple SRMs 156 can be provided. In some embodiments, each subsea equipment element interfaces with its own SRM 156 which, in turn, interfaces with another SRM 156. As such, an SRM 156 may rout control commands from MCS 128 to a single networked end device 160 or multiple networked end devices 160. In some embodiments, SRMs 156 operate on industry standard TCP/IP protocols although other open and non-proprietary standards can be used. In the embodiment shown, SRMs 156 have hardware packaging suitable for a subsea environment. In some embodiments, SRMs 156 can be installed and removed from subsea equipment elements via a standard work class ROV 164 via MQC or other suitable connection technology. In some embodiments, SRMs 156 can be housed individually inside of a dedicated subsea enclosure or co-located inside of an enclosure with other networked end devices 160 based on project requirements.

In the embodiment shown, networked end devices 160 are physically attached/mounted to various elements of the subsea production equipment and connected to one or more SRMs 156 via suitable electrical or optical connections. All communications to and from networked end devices 160 occur via standard open and non-proprietary communications protocols such as Ethernet. In the embodiment shown, each networked end device 160 has a unique network address and can communicate directly with MCS 128 via one or more SRMs 156.

In the embodiment shown, jumpers/flying leads 152 provide a conduit to transmit hydraulic fluid, electrical power, and/or network communications between topsides and subsea equipment elements and provide connections between UTA/SDU 148 and one or more SRMs 156, between separate SRMs 156, and/or between SRMs and networked end devices 160. In some embodiments, jumpers/flying leads 152 include thermal insulation, buoyancy, and/or bend stiffening/restricting technology as needed to meet project requirements. In embodiments where hydraulics are not required for subsea operations, umbilical 144 and jumpers/flying leads 152 can only contain electrical and data network communications lines/channels.

In the embodiment shown, one or more MQC plates provide a subsea wet mate connection for hydraulics, power, and communication lines. Specifically, umbilical 144 and jumpers/flying leads 152 can connect to one or more of UTA/SDU 148, one or more SRMs 156, and/or networked end devices 160 via the one or more MQC plates. In some embodiments, these control connections can be installable and removable with a standard work class ROV 164 and can feature a secondary release mechanism for contingency and emergency operations. In some embodiments, MQC plates may feature Retlock® technology from AFGlobal Corporation.

Although optional to the disclosed embodiments, in the embodiment shown, an ROV 164 can be provided as an integral part of the subsea infrastructure so a topsides operator can pilot the ROV through the subsea environment using integrated topsides controls provided by MCS 128. In the embodiment shown, ROV 164 can connect to subsea production equipment elements using MQC connection technology and can contain various buoyancy and electronic control elements. In the embodiment shown, ROV 164 can install and/or remove the connections between umbilical 144, UTA/SDU 148, one or more SRMs 156, and one or more networked end devices 160 and can perform maintenance and other necessary functions in the subsea environment. In some systems, ROV 164 can be deployed separately and independently of any subsea production control and/or monitoring systems. Alternatively, observation and monitoring functionality can be implemented through a series of networked end devices 160 such as stationary or articulating cameras, stationary or articulating lights, and other controllable monitoring and/or sensing devices that can be mounted on the subsea production equipment.

FIG. 2 shows an exemplary subsea Christmas tree 200 that can be used with the control system 100 according to an embodiment of the disclosure. In some embodiments, Christmas tree 200 can be used as the one or more Christmas trees 120 shown in FIG. 1. In the embodiment shown, Christmas tree 200 includes various connection ports or valves 204 that enable connection of Christmas tree 200 to various subsea equipment elements such as manifold 116. Although connection ports 204 are depicted for reference, they are included in many standard Christmas trees to provide standard connections and are not integral to the described embodiments of the subsea open control systems. In the embodiment shown, Christmas tree 200 includes at least one electro-hydraulic port 208 that receives an electro-hydraulic connection from UTA/SDU 148. In the embodiment shown, the electro-hydraulic connection between UTA/SDU 148 is via a jumper/flying lead 152 and provides both hydraulic power/fluid to Christmas tree 200 from HPU 132 and electric power from SPCU 136. In the embodiment shown, Christmas tree 200 includes at least one expansion port 212 that enables a redundant connection of Christmas tree 200 to UTA/SDU 148, a connection to a connection port of another subsea equipment element, or a connection to an SRM 156 located on another subsea equipment element. In the embodiment shown, Christmas tree 200 includes one or more SRM ports 216 for connecting to one or more SRMs 156. In the embodiment shown, one or more SRMs 156 are coupled to Christmas tree 200 and directly connect Christmas tree 200 to the network. SRMs 156 enable direct control of Christmas tree 200 from MCS 128 by sending and receiving commands between MCS 128 and Christmas tree 200 using a unique network address of Christmas tree 200. In some embodiments, SRMs 156 can be directly connected to other SRMs 156 via connections such as jumpers/flying leads 152 or may be connected to other SRMs 156 via an expansion port 212 of Christmas tree 200. In the embodiment shown, the jumpers/flying leads 152 can connect to ports 208 and 212 and SRMs 156 can connect to ports 216 of Christmas tree 200 via connection plates such as MQC plates 220. In some embodiments, MQC plates 220 can be connected to and/or removed from Christmas tree 200 by ROV 164. Because Christmas tree 200 can connect to the network directly via one or more SRMs 156, a conventional SCM is not needed and is preferably removed from the control system.

FIG. 3 shows an exemplary UTA/SDU 300 that can be used with the control system 100 according to an embodiment of the disclosure. In some embodiments, UTA/SDU 300 can be used as UTA/SDU 148 shown in FIG. 1. In the embodiment shown, UTA/SDU 300 connects to a subsea end of umbilical 144 at umbilical termination point 304. Through this connection, UTA/SDU 300 sends and receives hydraulic flow, power, and network control commands from MCS 128 for operation of various subsea equipment elements. In the embodiment shown, UTA/SDU 300 includes a manifold connection port 308 for connecting to a manifold such as manifold 116. This connection can be via a jumper/flying lead 152. Through this connection, UTA/SDU 300 sends and receives hydraulic flow and power to manifold 116 from HPU 132 and SPCU 136. In the embodiment shown, UTA/SDU 300 includes at least one SRM connection port 312 for connecting to an SRM such as SRM 156. Through this connection, UTA/SDU 300 sends and receives network control commands to SRM 156 from MCS 128. In some embodiments, SRM 156 can be connected directly to SRM connection port 312 via an MQC connection plate (i.e., an outboard connection). Alternatively, SRM 156 can be connected to SRM connection port 312 via a jumper/flying lead 152. In the embodiment shown, UTA/SDU 300 includes one or more expansion ports 316. In some embodiments, expansion ports 316 function in a similar way to SRM connection port 312 in that expansion ports 316 enable a connection between UTA/SDU 300 and additional SRMs 156 either directly via an MQC connection plate or via a jumper/flying lead 152. Through these connections, UTA/SDU 300 sends and receives network control commands to the additional SRMs 156 from MCS 128. In this way, additional SRMs 156 can be easily added to the network, resulting in good network scalability. In addition, this modular design also facilitates flexibility and scalability in the overall subsea field architecture. Since the SRMs 156 located subsea provide an open and non-proprietary network similar to the Internet, additional subsea processing equipment elements can be connected to expansion ports 316 and be visible on the network to the topsides MCS 128.

FIG. 4 shows an exemplary modular SRM 400 for use with the control system 100 according to an embodiment of the disclosure. In some embodiments, modular SRM 400 can be used as the one or more SRMs 156 shown in FIG. 1. Through the implementation of control system 100, various hardware elements can be adapted or changed from conventional designs to more compact and modular configurations. In order to enable direct communication between MCS 128 and networked end devices 160, control system 100 eliminates a traditional SCM. Conventional SCMs have a large size and complex mounting base arrangements. Additionally, they are difficult to maintain and replace. The retrieval of traditional SCMs requires the use of specialized tooling and a winch line in most cases due to their size, weight, and complex electro-hydraulic mounting base structure. On the contrary, modular SRM 400 occupies a significantly smaller footprint when installed on subsea production equipment and can be mounted outboard of the main structure of the equipment element via an MQC plate or other type of connection plate. This can further reduce the overall cost and size of the equipment element. Additionally, a modular SRM 400 mounted on an outboard MQC plate can be easily retrieved and replaced by an ROV 164 using a standard torque tool and manipulator configuration. In the embodiment shown, modular SRM 400 includes a modular housing 404, network switching elements 408, one or more connection ports 412, and one or more networked end device ports 416. In the embodiment shown, modular housing 404 comprises one or more waterproof materials such as metal, glass, plastic, or the like fastened together with one or more fastening elements such as rivets, bolts, screws, or the like to provide a protective, waterproof shell for housing network switching elements 408 and protecting them from the subsea environment. In the embodiment shown, modular housing 404 includes at least one connection port 412 configured to connect modular SRM 400 to UTA/SDU 148 and/or another SRM 156. In the embodiment shown, connection port 412 is configured to couple to an MQC connection plate and/or a jumper/flying lead 152. In the embodiment shown, modular housing 404 includes at least one networked end device port 416 configured to connect modular SRM 400 to one or more networked end devices 160. With this configuration, modular SRM 400 is configured to receive and send control and/or status commands from MCS 128 via connection port 412 and receive and send control and/or status commands to one or more networked end devices 160 via one or more networked end device ports 416.

FIG. 5 shows an exemplary multiple quick connect (MQC) plate 500 for use with the control system 100 according to an embodiment of the disclosure. Specifically, FIG. 5 shows an example of two modular SRMs 156 mounted to the MQC plate 500. In some embodiments, there may be any practical number of SRMs 156 or other networked end devices 160 mounted to the MQC plate arrangement 500. In some embodiments, MQC plate 500 can be used as the one or more MQC plates 220 shown in FIG. 2. Some or all of the system connections discussed above for control system 100 can be implemented via an MQC plate 500. In the embodiment shown, MQC plate 500 includes a fixed “inboard” component 504 fixedly disposed on an outer surface of a subsea equipment element. In the embodiment shown, MQC plate 500 includes an “outboard” component 508 disposed on one or more connecting components such as umbilical 144 or jumper/flying lead 152 or on one or more SRMs 156. In the embodiment shown, “inboard” component 504 includes one or more couplings 512 configured to receive hydraulic flow tubes, power lines, and/or network control connections located in umbilical 144, jumper/flying lead 152, and/or SRM 156. In the embodiment shown, “outboard” component 508 includes a port 516 connecting “outboard” component 508 to umbilical 144, jumper/flying lead 152, and/or SRM 156. In the embodiment shown, “outboard” component 508 includes an attachment device 520 operable with a standard torque tool. In some embodiments, an ROV 164 can operate attachment device 520 to install and remove “outboard” component 508 from “inboard” component 504 in a quick and efficient manner.

FIG. 6 shows an exemplary system diagram 600 of a subsea open-standard control system having a daisy chain subsea network configuration according to an embodiment of the disclosure. By using expansion ports 212 and 316 and/or connection ports 412, the topsides operator can daisy chain network connections on subsea production equipment in addition to providing a traditional hub and spoke configuration. System diagram 600 is similar to that shown in FIG. 1. However, diagram 600 illustrates a daisy chain network topology. In the embodiment shown, Christmas trees 120 are connected to UTA/SDU 148 via one or more jumper/flying leads 152 coupled to SRMs 156. In the embodiment shown, each Christmas tree 120 has its own individual SRM 156. However, only the SRM 156 of the Christmas tree 120 closest to UTA/SDU 148 is directly connected to UTA/SDU 148. This connection could be via an expansion port 316 disposed on UTA/SDU 148. The SRMs 156 of the Christmas trees 120 farther away from UTA/SDU 148 are not directly connected to UTA/SDU 148 but are instead directly connected to the SRM 156 of the Christmas tree 120 closest to UTA/SDU 148. This connection could be via a connection port 412 disposed on each SRM 156. In this way, additional subsea equipment components can be easily and efficiently connected to the network. In the embodiment shown, additional subsea components 604 are desired to be added to the network. In some instances, it may not be feasible to connect components 604 directly to UTA/SDU 148. For example, all expansion ports 316 of UTA/SDU 148 may be in use or components 604 may be located too far away from UTA/SDU 148 for a direct connection using a jumper/flying lead 152. In the embodiment shown, the SRMs 156 of the components 604 are connected in a daisy chain configuration to the SRM 156 of manifold 116 instead of directly connected to UTA/SDU 148. The ability to add additional nodes to the subsea network also creates the option to build in network redundancy by interconnecting multiple nodes to create a mesh network configuration. A mesh network topology allows a node to remain functional should one of the redundant network connections become inoperable.

FIG. 7A shows an exemplary system flowchart 700 of an operation of a conventional subsea control system. In the embodiment shown, a topsides human operator 704 interacts with a topsides HMI 708 that runs proprietary non-user-configurable software and is connected to SPCU 712 via proprietary network cables and protocols. In the embodiment shown, SPCU 712 converts the HMI data into an appropriate medium (such as fiber, communications on power, etc.) to send via an umbilical 716. In the embodiment shown, HPU 720 controls hydraulic fluid pressure and volume and distributes appropriate hydraulic data through umbilical 716. In the embodiment shown, umbilical 716 transmits hydraulic, electric, and data communications between the topside sources and a UTA/SDU 724. All lines can be redundant to increase reliability and data transfer can be via specific mediums such as fiber optic, copper, and/or communications on power systems. In the embodiment shown, a hydraulic distribution unit (HDU) 728 distributes hydraulic power from umbilical 716 to connected subsea equipment. In the embodiment shown, an electronic distribution unit (EDU) 732 distributes proprietary network connections to connected subsea equipment. In the embodiment shown, a hydraulic flying lead (HFL) 736 and an electronic flying lead (EFL) 740 transmit hydraulic fluid, electrical power, and data communications between UTA/SDU 724 and the connected subsea equipment. All lines can be redundant to increase reliability. In the embodiment shown, SCM 744 has a single network address. In the embodiment shown, all of the networked end devices 748 shown are connected to SCM 744 via analog signals, digital serial protocols, and/or proprietary protocols. In the embodiment shown, HMI 708 cannot interface directly with networked end devices 748; it can only communicate with SCM 744, which interprets and relays information to and from networked end devices 748. In the embodiment shown, hydraulic fluid is directed to the appropriate networked end devices 748 based on interpretations of commands from HMI 708 by SCM 744. This process flow can result in data bottlenecks at SCM 744 and requires rigid architectures and the use of specific proprietary software and/or network protocols.

FIG. 7B shows an exemplary system flowchart 700 of an operation of a subsea open-standard control system such as control system 100 according to an embodiment of the disclosure. In the embodiment shown, topsides human operator 704 interacts with topsides HMI 708 that runs user-configurable software and is connected to SPCU 712 via standard Cat 5 or equivalent Ethernet cables or other open standard network cables. The process flow then proceeds in an identical fashion to that shown in FIG. 7A until it reaches UTA/SDU 724. In the embodiment shown, hydraulic distribution unit (HDU) 728 distributes hydraulic power from umbilical 716 to connected subsea equipment via hydraulic flying lead 736. In the embodiment shown, SRM 752 receives network traffic from the topside sources and distributes the network traffic via Ethernet or other open standard protocol to connected subsea equipment via electrical flying lead 740. All lines can be redundant to increase reliability and can be combined into a single bundled flying lead assembly that combines the functionality of hydraulic flying lead 736 and electrical flying lead 740. In the embodiment shown, SRM 756 routes network traffic to and from networked end devices 748. In the embodiment shown, all of the networked end devices 748 shown have unique individual network addresses and are connected to SRM 756 via Ethernet data link or other open standard protocol. In the embodiment shown, HMI 708 interfaces directly with networked end devices 748 via SRM 756. In the embodiment shown, hydraulic fluid is directed to the appropriate networked end devices 748 based on direct HMI commands to hydraulic pilot valves in SRM 756. In the embodiment shown, one or more expansion ports 760 are available to expand and scale the subsea electro-hydraulic network as needed to meet project demands. This enables scalability and connection of a mesh network topology for added reliability. In the embodiment shown, expansion ports 760 can be interfaced with SRM 756 or UTA/SDU 724.

FIG. 8 shows an exemplary control method 800 implemented by a subsea open-standard control system according to an embodiment of the disclosure. In one embodiment of the disclosure, method 800 can be implemented by control system 100 shown in FIG. 1. In the embodiment shown in FIG. 8, method 800 begins at step 804 by receiving, by MCS 128, one or more communications from one or more SRMs 156 and one or more networked end devices 160 connected to a control network. In the embodiment shown, the control network is an open and non-proprietary network such as Ethernet that communicates via TCP/IP protocols. However, any suitable open and non-proprietary network can be used. In some embodiments, the communications may be received by MCS 128 in response to one or more monitoring or query communications sent by MCS 128 to the network. In some embodiments, networked subsea devices such as SRMs 156 and networked end devices 160 can send communications to MCS 128 when they are connected into the network so MCS 128 can communicate directly with all connected SRMs 156 and networked end devices 160. In the embodiment shown, method 800 continues at step 808 by receiving, by MCS 128 via an HMI such as HMI 708 shown in FIG. 7B, one or more control commands from a human operator such as operator 704 shown in FIG. 7B for controlling a state or operation of one or more of the networked end devices 160. In the embodiment shown, the operator may issue one or more control commands to the HMI using any suitable input device such as a keyboard, mouse, microphone, touchscreen, button, knob, or the like. In the embodiment shown, method 800 continues at step 812 by sending, by MCS 128, the one or more control commands through the network to one or more SRMs 156. The one or more SRMs 156 receive the one or more control commands and rout the one or more control commands to the intended networked end device 160. In the embodiment shown, method 800 continues at step 816 by the control system implementing one or more particular functions of the intended networked end device 160 corresponding to the one or more control commands issued by the topsides operator. In this way, the topsides operator, via MCS 128, can communicate directly with each networked SRM 156 and networked end device 160 because each SRM 156 and each networked end device 160 has its own unique destination address.

FIG. 9 shows an exemplary routing method 900 implemented by a subsea open-standard control system according to an embodiment of the disclosure. In one embodiment of the disclosure, method 900 can be implemented by control system 100 shown in FIG. 1 and may be implemented as a subroutine to method 800. In the embodiment shown in FIG. 9, method 900 begins at step 904 when an SRM 156 analyzes a control command received from MCS 128 and determines a destination network address of the control command. In the embodiment shown, the destination network address is inserted into the control command by MCS 128 and corresponds to a network address of a particular networked end device 160. In the embodiment shown, method 900 continues at step 908 by the SRM 156 matching the destination network address of the control command with a unique destination address of a particular networked end device 160. In some embodiments, the SRM 156 may send queries to the devices connected to the network nodes to receive the unique destination addresses of each node and compile a destination address table. In the embodiment shown, method 900 continues at step 912 by the SRM 156 routing the control command to the networked end device 160 having a unique destination address that matches the destination network address of the control command. In some embodiments, the SRM 156 determines that the networked end device 160 is not directly connected to the SRM 156 but is coupled to a separate SRM 156 in a daisy chain configuration similar to the embodiment shown in FIG. 6. In this situation, the SRM 156 determines the separate SRM 156 that is connected to the networked end device 160 that matches the destination network address of the control command and routes the control command to that separate SRM 156. The separate SRM 156 then forwards the control command to the networked end device 160. In this way, MCS 128 can communicate directly with each SRM 156 and each networked end device 160 connected to the network.

FIG. 10 shows an exemplary remote operating vehicle (ROV) control method 1000 implemented by a subsea open-standard control system according to an embodiment of the disclosure. In one embodiment of the disclosure, method 1000 can be implemented by control system 100 shown in FIG. 1. In the embodiment shown in FIG. 10, method 1000 begins at step 1004 by receiving an ROV control command for piloting an ROV from an operator by MCS 128 via an HMI and sending, by MCS 128, the ROV control command to an ROV (e.g., ROV 164) connected to the network. In the embodiment shown, a SRM 156 receives the ROV control command, matches the destination network address of the control command with the unique network address of ROV 164, and routes the control command to ROV 164. In this way, MCS 128 can communicate directly with each ROV 164 connected to the network. In the embodiment shown, method 1000 continues at step 1008 by ROV 164 receiving the ROV control command from a SRM 156 and performing a function corresponding to the ROV control command. In this way, the topsides operator can pilot and perform functions with ROV 164. In the embodiment shown, an important function of the ROV 164 is to enable expansion of the network by installing and removing networked end devices 160 from the network. In the embodiment shown, method 1000 continues at step 1012 by connecting, using the ROV 164, an additional SRM 156 and/or networked end device 160 to the network via an expansion port. In some embodiments, the expansion port can be an expansion port 212 of Christmas tree 200, an expansion port 316 of UTA/SDU 300, or a connection port 412 of modular SRM 400. In the embodiment shown, ROV 164 can connect the additional SRM 156 and/or networked end device 160 to the expansion port using a MQC plate such as that shown in FIG. 5. In the embodiment shown, method 1000 continues at step 1016 by disconnecting, using the ROV 164, a SRM 156 and/or networked end device 160 from the network. In the embodiment shown, ROV 164 can disconnect the SRM 156 and/or networked end device 160 by decoupling a MQC plate such as that shown in FIG. 5. In this way, network nodes can be easily and efficiently installed and removed from the network by the ROV 164 using conventional torque tools.

The above specification and examples provide a complete description of the structure and use of illustrative embodiments. Although certain embodiments have been described above with a certain degree of particularity, or with reference to one or more individual embodiments, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the scope of this invention. As such, the various illustrative embodiments of the methods and systems are not intended to be limited to the particular forms disclosed. Rather, they include all modifications and alternatives falling within the scope of the claims, and embodiments other than the one shown may include some or all of the features of the depicted embodiment. For example, elements may be omitted or combined as a unitary structure, and/or connections may be substituted. Further, where appropriate, aspects of any of the examples described above may be combined with aspects of any of the other examples described to form further examples having comparable or different properties and/or functions, and addressing the same or different problems. Similarly, it will be understood that the benefits and advantages described above may relate to one embodiment or may relate to several embodiments.

The claims are not intended to include, and should not be interpreted to include, means-plus- or step-plus-function limitations, unless such a limitation is explicitly recited in a given claim using the phrase(s) “means for” or “step for,” respectively. 

1. A subsea open-standard control system, the system comprising: a topsides master control station (MCS) comprising: a human-machine interface including a computing device having at least one processor configured to execute instructions, and a network interface configured to communicate commands to a network using an open and non-proprietary network protocol; at least one subsea network router module (SRM) comprising: a modular housing configured to be disposed on a subsea structure, and a plurality of network switches disposed within the housing, the network switches configured to operate using the open and non-proprietary networking protocol; and at least one subsea networked end device connected to the at least one SRM, each subsea networked end device having a unique network address and configured to communicate directly with the MCS via the at least one SRM using the open and non-proprietary networking protocol.
 2. The system of claim 1, further comprising: at least one topsides hydraulic power unit configured to control hydraulic fluid flow to the at least one subsea networked end device.
 3. The system of claim 1, further comprising: at least one subsea power and communications unit configured to interface with the MCS and interface with at least one subsea umbilical to provide clean power and network communications to the at least one subsea umbilical.
 4. The system of claim 3, further comprising: at least one subsea distribution unit (SDU) configured to connect the at least one SRM to the at least one subsea umbilical.
 5. The system of claim 3, further comprising: a plurality of multi quick connection (MQC) plates configured to: connect the at least one SDU to the at least one SRM, and connect the at least one SRM to the at least one subsea networked end device.
 6. The system of claim 5, further comprising: at least one remotely operated vehicle (ROV) configured to communicate directly with the MCS via the at least one SRM using the open and non-proprietary networking protocol; where the at least one ROV is configured to install and remove the plurality of MQC plates and the at least one SRM.
 7. The system of claim 4, comprising a plurality of SRMs and a plurality of subsea networked end devices, where each of the plurality of subsea networked end devices is connected to a separate one of the plurality of SRMs and at least one of the plurality of SRMs is connected to the at least one SDU.
 8. The system of claim 1, where the at least one SRM is configured to be directly mounted on the at least one subsea networked end device.
 9. The system of claim 1, where the at least one SRM further comprises at least one connection port configured to connect an additional subsea networked end device having a unique network address to the at least one SRM.
 10. A method of operating a subsea open-standard control system comprising a topsides master control station (MCS) including a computing device having at least one processor, the method comprising: receiving, by the MCS, at least one communication indicating that at least one subsea network router module (SRM) and at least one subsea networked end device having a unique network address are connected to a network using an open and non-proprietary networking protocol; receiving, by the MCS via a human-machine interface, at least one control command for controlling the at least one subsea networked end device; sending, by executing one or more instructions with the at least one processor, the at least one control command to the at least one SRM using the open and non-proprietary networking protocol, where the at least one SRM routes the at least one control command to the at least one subsea networked end device and enables direct communication between the MCS and the at least one subsea networked end device; and implementing a function of the at least one subsea networked end device corresponding to the at least one control command.
 11. The method of claim 10, where the at least one SRM comprises at least one connection port configured to connect an additional subsea networked end device having a unique network address to the at least one SRM via a separate network connection, the separate network connection using the open and non-proprietary networking protocol.
 12. The method of claim 10, where at least one subsea distribution unit (SDU) comprises at least one expansion port configured to connect an additional SRM to the network via a separate network connection, the separate network connection using the open and non-proprietary networking protocol.
 13. The method of claim 12, where each of a plurality of subsea networked end devices is connected to a separate one of a plurality of SRMs and at least one of the plurality of SRMs is connected to the at least one SDU.
 14. The method of claim 10, further comprising: analyzing, by the at least one SRM, a destination network address of the at least one control command; matching, by the at least one SRM, the destination network address of the at least one control command to the unique network address of the at least one subsea networked end device; and routing, by the at least one SRM, the at least one control command to the subsea networked end device having the unique network address that matches the destination network address.
 15. The method of claim 10, further comprising: controlling, by the MCS, hydraulic fluid flow to the at least one subsea networked end device.
 16. A method of operating a subsea open-standard control system comprising a topsides master control station (MCS) including a computing device having at least one processor, the method comprising: determining, by the MCS, that a network using an open and non-proprietary networking protocol can support an addition of at least one expansion network node to the network, the at least one expansion network node including one or more of a subsea network router module (SRM) and a subsea networked end device having a unique network address; and expanding, by the MCS, the network by adding the at least one expansion network node to the network.
 17. The method of claim 16, where expanding the network includes attaching the SRM to an expansion port of a subsea distribution unit (SDU) connected to the network.
 18. The method of claim 16, where expanding the network includes attaching the subsea networked end device to a connection port of a SRM connected to the network.
 19. The method of claim 16, where expanding the network includes connecting the at least one expansion network node to the network in a daisy chain network configuration.
 20. The method of claim 16, further comprising: adding a redundant network connection to the at least one expansion network node in a mesh network configuration.
 21. A method of operating a subsea open-standard control system comprising a topsides master control station (MCS) including a computing device having at least one processor, the method comprising: sending, by the MCS via an open and non-proprietary networking protocol, at least one control command directly to a subsea networked end device connected to a network, where the at least one control command is routed to the subsea networked end device by a subsea network router module (SRM) using a unique network address of the subsea networked end device.
 22. The method of claim 21, where the at least one control command is sent directly to the subsea networked end device from the MCS without sending the at least one control command through a subsea control module (SCM). 